US Patent # 5,996,627, 6,241,487 RHDF2 Hazardous Duty ...sp.salesmrc.com/pdfs/rhdf2dl1sm_haz_duty.pdf · US Patent # 5,996,627, 6,241,487 US Patent # 7,521,921 Pending Other US Patents

rhdf2dl1sm_haz duty-rev0915

SAFETY PRECAUTIONSEngineering, Performance and Construciton Data ............................................................................ 1Explanation of Pump Nomenclature .................................................................................................. 2Performance Curve ........................................................................................................................... 3Dimensions ........................................................................................................................................ 4Important Installation Information ...................................................................................................... 5Principle of Pump Operation .............................................................................................................. 7Principle of AirVantage ...................................................................................................................... 7Installation and Start-Up .................................................................................................................... 7Air Supply .......................................................................................................................................... 7Air Line Moisture ................................................................................................................................ 7Air Valve Lubrication .......................................................................................................................... 7Air Inlet and Priming .......................................................................................................................... 7Between Uses ................................................................................................................................... 7Pump Troubleshooting ....................................................................................................................... 9AirVantage Troubleshooting ...................................................................................................... 10-11Composite Repair Parts List ........................................................................................................... 12Composite Repair Parts Kits ........................................................................................................... 13Composite Repair Parts Drawing: Wetted Side ............................................................................... 14Diaphragm and Check Valve Servicing ........................................................................................... 15Composite Repair Parts Drawing: Air Side ...................................................................................... 16

Intermediate and AirVantage Sensor Servicing ............................................................................... 17Air Valve Servicing, Assembly Drawings and Parts List .................................................................. 18Air Valve Servicing with Stroke Indicators, Assembly Drawings and Parts List .............................. 19Pilot Valve and Actuator Plunger Servicing .................................................................................... 20Pulse Output Kits and Drawing ....................................................................................................... 21Composite Repair Parts Drawing - AirVantage Unit ........................................................................ 23AirVantage Servicing - Pilot Valve and Pressure Regulator ............................................................ 24AirVantage Servicing - Power Generation Module .......................................................................... 25AirVantage Servicing - Control Module ........................................................................................... 26AirVantage Servicing - Sensor Assembly ....................................................................................... 27AirVantage Servicing - Poppet Valve Drawing ................................................................................. 28AirVantage Servicing - Poppet Valve .............................................................................................. 29AirVantage Servicing - Check Valve ............................................................................................... 30Grounding the Pump ...................................................................................................................... 31Pumping Hazardous Liquids - Shutdown Procedure ...................................................................... 32Converting the Pump for Piping Exhaust Air ................................................................................... 32Material Codes for the Last 3 Digits of the Part Number ................................................................ 33CE Declaration of Conformity - Machinery ...................................................................................... 34CE Declaration of Conformity - ATEX .............................................................................................. 35Declaration of Conformity - IECEx ................................................................................................... 36

RHDF2 Hazardous DutyHeavy Duty Flap ValveAirVantage Design Level 1Table of Contents

SERVICE & OPERATING MANUAL

Warren Rupp, Inc. • A Unit of IDEX Corporation • 800 N. Main St., Mansfield, Ohio 44902 USA Telephone (419) 524-8388 • Fax (419) 522-7867 • warrenrupp.com ©Copyright 2015 Warren Rupp, Inc. All rights reserved.

US Patent # 5,996,627, 6,241,487 US Patent # 7,521,921 Pending Other US Patents Pending

Page 1

0518

The enclosure is non-conducting and may generate an ignition-capable level of electrostatic charges under certain extreme conditions. The user should ensure that the equipment is not installed in a location where it may be subjected to external conditions (such as high-pressure steam) which might cause a build-up of electrostatic charges on non-conducting surfaces. Additionally, cleaning of the equipment should be done only with a damp cloth.”

RecyclingWarren Rupp is committed to protecting the environment and preventing pollution for the benefit of our employees, as well as local and global communities, now and in the future.

Many components of SANDPIPER® Metallic AODD pumps are made of recyclable materials (see chart on page 32 for material specifications). We en-courage pump users to recycle worn out parts and pumps whenever possible. Follow all applicable guidelines if hazardous material has been pumped.

Cautions - Read Operating and Safety Precautions First

When used for toxic or aggressive fluids, the pump should always be flushed clean prior to disassembly.

In the event of diaphragm rupture, pumped material may enter the air end of the pump, and be discharged into the atmosphere. If

pumping a product which is hazardous or toxic, the air exhaust must be piped to an appropriate area for safe disposition.

IMPORTANTBefore installation and start-up of the pump read these safety warnings and instructions in this manual

completely. It is the responsibility of the purchaser to retain this manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.

WARNING WARNING

Take action to prevent static sparking. Fire or explosion can result, especially when handling flammable liquids. The pump, piping, valves,

containers or other miscellaneous equipment must be grounded. (See page 30)

WARNING

B e f o r e m a i n t e n a n c e or repair, shut off the c o m p r e s s e d a i r l i n e , bleed the pressure, and disconnect the air line from

the pump. The discharge line may be pressurized and must be bled of its pressure.

WARNING

This pump is pressurized internally with air during operation. Always make certain that all bolts are in good condition and that all of the correct bolts are

reinstalled during assembly.

WARNING

Airborne particles and loud noise hazards.Wear ear and eye protection.

WARNING

B e f o r e d o i n g a n y maintenance on the pump, be certain all pressure is completely vented from the pump, suction, discharge,

piping, and all other openings and connections. Be certain the air supply is locked out or made non-operational, so that it cannot be started while work is being done on the pump. Be certain that approved eye protection and protective clothing are worn at all times in the vicinity of the pump. Failure to follow these recommendations may result in serious injury or death.

WARNING

Before pump operation, i n s p e c t a l l g a s k e t e d fasteners for looseness caused by gasket creep. Re-torque loose fasteners to

prevent leakage. Follow recommended torques stated in this manual.

CAUTION

CAUTIONP u m p n o t d e s i g n e d , tested or certif ied to be powered by compressed natural gas. Powering the

pump with natural gas will void the warranty.

Use safe practices when lifting

WARNING

kg

Special Conditions for Safe Use:• For the safe operation of the equipment, it is necessary for the air supply

line to be in a safe area• The cable entry hole should be fitted with a suitably certified cable gland• For the safe operation of the equipment, the pneumatic pump should be

grounded• The enclosure is non-conducting and may generate an ignition-capable

level of electrostatic charges under certain extreme conditions. The user should ensure that the equipment is not installed in a location where it may be subjected to external conditions (such as high pressure steam) which might cause a build-up of electrostatic charge on the non-conducting surfaces. Additionally, cleaning of the equipment should be done only with a damp cloth.

rhdf2dl1sm_haz duty-rev0915 Model RHDF2 Hazardous Duty Page 1

Nitrile: General purpose, oil-resistant. Shows good solvent, oil, water and hydraulic fluid resistance. Should not be used with highly polar solvents like acetone and MEK, ozone, chlorinated hydrocarbons and nitro hydrocarbons. EPDM: Shows very good water and chemical resistance. Has poor resistance to oil and solvents, but is fair in ketones and alcohols. Neoprene: All purpose. Resistant to vegetable oil. Generally not affected by moderate chemicals, fats, greases and many oils and solvents. Generally attacked by strong oxidizing acids, ketones, esters, nitro hydrocarbons and chlorinated aromatic hydrocarbons. Santoprene®:: Injection molded thermoplastic elastomer with no fabric layer. Long mechanical flex life. Excellent abrasion resistance.

Virgin PTFE: Chemically inert, virtually impervious. Very few chemicals are known to react chemically with PTFE- molten alkali metals, turbulent liquid or gaseous fluorine and a few fluoro-chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures.

FKM (Fluorocarbon): Shows good resistance to a wide range of oils and solvents; especially all aliphatic, aromatic and halogenated hydrocarbons, acids, animal and vegetable oils. Hot water or hot aqueous solutions (over 70°F) will attack FKM.

Polypropylene:

UHMW Polyethylene:

Materials Maximum Minimum

Quality SystemISO 9001 Certified

Environmental Management System ISO 14001 Certified

Operating Temperatures

INTAKE/DISCHARGE PIPE SIZE2" NPT (internal)

CAPACITY0 to 130 gallons per minute(0 to 492 liters per minute)

AIR VALVENo-lube, no-stall

design

SOLIDS-HANDLINGUp to 2 in. (50mm)

HEADS UP TO125 psi or 289 ft. of water

(125 psi or 8.6 bar inlet) (8.6 bar or 88 meters)

DISPLACEMENT/STROKE.47 Gallon / 1.77 liter

CAUTION! Operating temperature limitations are as follows:

190° F 88° C

-10° F -23° C

280° F 138° C

-40° F -40° C

200° F 93° C

-10° F -23° C

275° F 135° C

-40° F -40° C

220° F 104° C

-35° F -37° C

350° F 177° C

-40° F -40° C

180° F 82° C

32° F 0° C

180° F 82° C

32° F 0° C

For specific applications, always consult The Warren Rupp Chemical Resistance Chart

SANDPIPER® pumps are designed to be powered only by compressed air.

RHDF2 Hazardous DutyAirVantage Design Level 1Heavy Duty FlapAir-OperatedDouble Diaphragm Pump

ENGINEERING, PERFORMANCE& CONSTRUCTION DATA

US Patent # 5,996,627, 6,241,487 US Patent # 7,521,921 Pending Other US Patents Pending

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Explanation of Pump Nomenclature, RHDF2 · Design Level 1· Flap Valve

Meanings of Abbreviations:

A = Compressed Fibre DC = Die Cast PS = Plated Steel SS/I = Stainless Steel seat w/EPDM O-Ring AL = Aluminum H = Hytrel® S = Santoprene® T = PTFEB = Nitrile I = EPDM SS = Stainless Steel U = Urethane CI = Cast Iron N = Neoprene V = FKM (Fluorocarbon) F = FDA Accepted White Nitrile

Hytrel is a registered tradename of E.I. du Pont. Santoprene is a registered tradename of Exxon Mobil Corp.

Outer Inner Flap RHDF2 Manifold Outer Inner Diaphragm Diaphragm Intermediate Diaphragm Valve Hard- Diaphragm Valve Sealing Shipping AirVantage Type 1 Elbow Chamber Chamber Plate Plate Housing Rod Seat ware Material Rings Wt. (lbs.) Options DA-6-A AL380DC AL380DC AL380DC PS PS 356-T6AL 416SS 316SS PS N U N 86 Y DB-6-A AL380DC AL380DC AL380DC PS PS 356-T6AL 416SS 316SS PS B B B 86 Y DV-6-A AL380DC AL380DC AL380DC PS PS 356-T6AL 416SS 316SS PS V V V 86 Y DN-6-A AL380DC AL380DC AL380DC PS PS 356-T6AL 416SS 316SS PS N N N 86 Y DI-6-A AL380DC AL380DC AL380DC PS PS 356-T6AL 416SS 316SS PS I I I 86 Y DP-6-A AL380DC AL380DC AL380DC PS PS 356-T6AL 416SS 316SS/I PS S S I 86 Y DR-6-A AL380DC AL380DC AL380DC PS PS 356-T6AL 416SS 316SS PS H H N 86 Y DA-6-I-A CI CI AL380DC PS PS 356-T6AL 416SS 316SS PS N U N 133 Y DB-6-I-A CI CI AL380DC PS PS 356-T6AL 416SS 316SS PS B B B 133 Y DV-6-I-A CI CI AL380DC PS PS 356-T6AL 416SS 316SS PS V V V 133 Y DN-6-I-A CI CI AL380DC PS PS 356-T6AL 416SS 316SS PS N N N 133 Y DI-6-I-A CI CI AL380DC PS PS 356-T6AL 416SS 316SS PS I I I 133 Y DR-6-I-A CI CI AL380DC PS PS 356-T6AL 416SS 316SS PS H H N 133 Y DP-6-I-A CI CI AL380DC PS PS 356-T6AL 416SS 316SS/I PS S S I 133 Y DA-6-S-A ‡SS ‡SS AL380DC ‡SS PS 356-T6AL 416SS 316SS PS N U N 133 Y DB-6-S-A ‡SS ‡SS AL380DC ‡SS PS 356-T6AL 416SS 316SS PS B B B 133 Y DF-6-S-A ‡SS ‡SS AL380DC ‡SS PS 356-T6AL 416SS 316SS PS F F F 133 Y DV-6-S-A ‡SS ‡SS AL380DC ‡SS PS 356-T6AL 416SS 316SS PS V V V 133 Y DN-6-S-A ‡SS ‡SS AL380DC ‡SS PS 356-T6AL 416SS 316SS PS N N N 133 Y DI-6-S-A ‡SS ‡SS AL380DC ‡SS PS 356-T6AL 416SS 316SS PS I I I 133 Y DP-6-S-A ‡SS ‡SS AL380DC ‡SS PS 356-T6AL 416SS 316SS/I PS S S I 133 Y DR-6-S-A ‡SS ‡SS AL380DC ‡SS PS 356-T6AL 416SS 316SS PS H H N 133 Y

X = AirVantage ATEX CertifiedY = US Hazardous Duty


Performance Curve, RHDF2 Design Level 1

0 20 40 60 80 100 120 140 160 180

500400300200100

100

90

80

70

60

50

40

30

20

10

0

BAR

PSI

1

2

3

4

5

6

7

0

10 (17)

20 (34)

30 (51)

40 (68)

50 (85)

60 (102)

(119)70

100 PSI (6.9 Bar)

80 PSI (5.5 Bar)

60 PSI (4.1 Bar)

40 PSI (2.8 Bar)

20 PSI (1.4 Bar)

SCFM (M3/hr)

600

U.S. Gallons per minute

Liters per minute

HEA

DModel RHDF2 Performance Curve

CAPACITY

Performace based on the following: elastomer fitted pump, flooded suction, water at ambient conditions.The use of other materials and varying hydraulic conditions may result in deviations in excess of 5%.


Dimensions: RHDF2 Dimensions are ± 1/8"Figures in parenthesis = millimeters

19.87505

21.64550

1" NPT AIR INLET

20.30

OPTIONALVERTICALSUCTION

PORT

516

2.5765

17.68449

2.6267

2.6267

.256

9.81249

16.07408

16.43417

25.10637

8.48215

2" NPT SUCTION PORT

2" NPTDISCHARGE PORT

3/4" NPT EXHAUST

8.8822611.00

279

14.00355

10.25260

8X .50 [13] MTG. HOLE

BOTH SUCTION AND DISCHARGE PORTS AREAVAILABLE WITH 2" BSP CONNECTIONS


Warren Rupp TranquilizerLimited to 125 psi(Optional)

Flexible Connector

Pipe Connection(Style Optional)

Shut-O� Valve

Pressure Gauge

Drain Port

Mu�er(Optional Piped Exhaust)

FlexibleConnection

Dessicant Dryer(Optional)

Unregulated AirSupply to TranquilizerFilter RegulatorPN: 020.107.000

Shut O�Valve

Flexible Connector

Pipe Connection(Style Optional

Drain Port

Shut-O� Valve

VacuumGauge

Note: Pipe weight should not be supported by pump connections.

Suction Port

Discharge Port

Suggested Installation Guide

Important Installation InformationUse of the standard AODD Installation Guide is recommended for pumps fitted with AirVantage technology. Install shut-off valves on both the suction and discharge of the pump. (This will help limit the amount of product that enters the center section of the pump in the event of a diaphragm failure.) Using shut-off valves in conjunction with a drain port also provides a means of allowing the lines to be drained when maintenance needs to be conducted.

WARNINGIn the event of diaphragm rupture, pumped material may enter the air end of the pump, and be discharged into the atmosphere. If

pumping a product which is hazardous or toxic, the air exhaust must be piped to an appropriate area for safe disposition.

When the supply liquid level is above the air inlet of the pump, and a diaphragm fails, the pumped liquid or fumes can enter the air end through the point of failure. When a diaphragm failure is detected, it is best to close the shut-off valves and bleed the lines of product. This will limit the ability of the material being pumped to enter the AirVantage. Failure to do so may result in damage to the AirVantage and air distribution components.

If a diaphragm failure has been detected in pumps fitted with AirVantage, the following procedure for shut-down must be used:

1. Close the suction shut-off valve (this will limit any new product from entering the pump)2. Close the discharge shut-off valve (this will stop any product from reentering the pump)3. Close the air supply shut-off valve4. Drain the discharge line5. Drain the suction line6. Perform maintenance

Caution: When performing a direct spray washdown, aplug must be installed in place of the AirVantage muffler. Failure to do so may damage internal components. (See page 23)


This Page Intentionally Blank


PRINCIPLE OF PUMP OPERATION This ball valve fitted pump has been equipped with IDEX’s patented AirVantage equipment. To fully understand the operation of the AirVantage, one must first understand the basics of Air Operated Double Diaphragm (AODD) pumps. AODD’s are powered by compressed air. The compressed air is directed behind each of the flexible diaphragms by a Main Air Valve. Once the diaphragm has reached the end of its stroke, a Pilot Valve is mechanically actuated, sending an air signal back to the Main Air Valve which redirects air to the opposite diaphragm. This causes the diaphragm assemblies, which are connected by a common Diaphragm Rod, to move in a reciprocating action. Air is directed to the inboard side of the diaphragm, which is closest to the center of the pump. This is referred to as the air side of the diaphragm. The opposite side is commonly called the fluid side. Most AODD pumps have a 1:1 ratio design. This means, when the discharge of the pump is closed completely (dead headed), the maximum pressure the pump will create will be equal to the air pressure being applied to the pump. At this point, and only at this point, the diaphragm will be completely balanced. The air pressure is equivalent to the fluid pressure and there will be no movement of the diaphragm. If the pump is stroking, then the system is not balanced. There will be more pressure applied to the air side than fluid pressure on the fluid side. During each stroke of the pump there are two distinct operations that occur. One diaphragm is moving away from the center of the pump, moving fluid out of the Discharge Manifold, while the other diaphragm is moving toward the center, bringing fluid into the Suction Manifold. Considering that the pump has a common suction and discharge port, these two operations are separated from each other through a series of Check Valves.

PRINCIPLE OF AIRVANTAGE AirVantage is a special air side device which uses equipment that can accurately monitor the operation of the pump. Based on the monitored information, air is metered to the correct amount to perform the work required, and NOTHING MORE. Once the pump starts up, and the AirVantage is turned on, the LED indicator light will go through a series of patterns. Initially the light will be solid green. This indicates the AirVantage is allowing the pump to reach a steady state. Next, the light will pulse at a very rapid rate. This is called the learn phase. Learn is where the AirVantage monitors the pump in non-AirVantage mode. This will set the parameters for operation in AirVantage mode. In less than one minute, the pump will change tones. The LED indicator light will start an uneven blink when optimization has started. Optimization will be completed once the LED light is blinking in unison with the stroke rate of the pump. All this is completed without sacrificing a significant amount of flow.

INSTALLATION AND START-UP The pump should be located near the product being pumped, in order to keep the suction line as short as possible. Minimize the number of fittings between the product and the pump and maintain the line size, if possible. Better results will always be realized if the line size of the suction line is increased by one size. It's not recommended to hook up rigid pipe directly to the pump. Some method of expansion joint or vibration isolator should be used. A Warren Rupp Tranquilizer® is recommended to reduce the pulsation in the flow. If the fluid level is more than 10 feet (3 meters) above the level of the pump, a pressure regulating device may need to be added to the exhaust of the pump (Consult the factory for recommendations).

AIR SUPPLY The air supply pressure cannot exceed 125 psi (8.6 bar). The air line and associated components (filters, regulators, solenoids valves, etc.) should not be less than ½” (13 mm). However, 3/4" (19mm) or greater is preferred. An air line filter-regulator is necessary for the AirVantage installation. The required component (PN: 020.107.000) is available through the distributor. Rigid pipe should not be hooked directly to the air inlet of the AirVantage. A flexible hose should be installed to reduce the strain. Do not let the weight of the air line components be supported by the air inlet of the pump. Failure to provide a means of supporting the weight may result in damage to the pump. If the pump will be shut down for any extended length of time, it is recommended that the air supply to the pump should be shut off.

SPECIAL CONDITIONS FOR SAFE USEFor the safe operation of the equipment, it is necessary for the air supply to come from a safe area, therefore,the supplied air shall be clean.

AIR LINE MOISTURE Water in the compressed air supply can create problems such as icing and freezing of the exhaust air. The formation of ice in the exhaust can cause the pump to cycle erratically, degrade efficiency, or even stop the pump. Fitting the pump with the AirVantage technology reduces the exhaust temperature. This is due to more energy being extracted from every pulse of air. When more energy is extracted, the temperature of the air is reduced. Some method of air drying will be necessary. Most refrigerant dryers installed on compressors can reduce the dewpoint to about 40° F. This is normally adequate for most pumping applications. If further drying needs to occur due to internal ice build-up, a desiccant dryer can be installed. These air line dryers can lower the dewpoint to around -40° F.

AIR VALVE LUBRICATION The air valve and pilot valve are designed to operate without lubrication. There may be instances of personal preference or when extremely dry air is being used (instrument quality or nitrogen) that a small amount of lubrication will improve the life of the rubber components being used on the air side of the pump. The lubrication may be added using an air line lubricator (¾” PN: 020.051.001 – 1” PN: 020.052.001). At the point of operation use SAE 10 weight, non detergent oil at a maximum rate of 1 drop per hour for every 20 scfm (9.4 liters/sec) of air consumption. Consult the pump curve to determine this value. The smallest amount needed is preferred.

AIR INLET AND PRIMING To start the pump, make sure the AirVantage switch is in the off position. Increase the pressure until the pump starts to cycle. The pump stroke rate should slow slightly when the pump is primed. Once the pump is fully primed, increase the pressure at the regulator until the desired flow rate is achieved. Again, the pump curve can be used to derive this value. If increasing the pressure to the pump does not generate a higher flow rate, then cavitation has occurred. Back the regulator off slightly. To gain the most efficiency from the pump, try to run the pump fully primed at all times. BETWEEN USES When the pump is being used to move materials that tend to settle out or solidify, the pump should be flushed to prevent damage. The product that remains in the pump could dry and settle out. This could potentially cause damage to the diaphragms and/or check valves during restart. In freezing temperatures the pump must be completely drained between uses. Due to the addition of the new technology, it is recommended the air supply to the pump be shut off if the pump is going to be shut down for an extended length of time.




PUMP TROUBLESHOOTING

CAUTION! WHENEVER TROUBLESHOOTING OR PERFORMING ANY REPAIRS ON ANY IDEX AODD EQUIPMENT, ALWAYS REMOVE THE AIR SUPPLY LINE TO THE PUMP AND WEAR PROPER PERSONAL PROTECTIVE EQUIPMENT. PUMP WILL NOT CYCLE

What to Check: • The system head exceeds the air supply pressure to the pump.Corrective Action: • Increase the air inlet pressure to the pump. Most diaphragm pumps are designed for 1:1 pressure at zero flow.

What to Check:• Check ESADS+, including pilot valve assembly and main air valve assembly.Corrective Action: • Disassemble and inspect the main air distribution valve, pilot valve, and pilot valve actuator pins. Check for scores, wear, or damaged o-rings. Replace parts as necessary. Refer to the exploded view drawing and air valve section (P.18 & 20).

What to Check: • Blocked discharge line.Corrective Action: • Check for obstruction or closed discharge line.

What to Check: • Blocked pumping chamber.Corrective Action: • Disassemble and inspect wetted chambers of the pump. Remove or flush any obstructions. Refer to page 14 for disassembly.

PUMP CYCLES, BUT WILL NOT FLOW OR FLOW RATE IS UNSATISFACTORY

What to Check: • Restricted or undersized air line.Corrective Action: • Make sure there are no obstructions or restrictions in the air inlet to the pump. Install proper size air line and/or air line equipment. Refer to air supply section (p.7) air inlet plumbing recommendations.

What to Check: • Restricted or undersized suction piping.Corrective Action: • Make sure there are no obstructions or restrictions in the suction line or related suction components such as screens or strainers. Install the proper size suction line and/or equipment. It is recommended that any suction line components and pipe size be at least the same size as the suction line thread size to the pump. Though best results will always be realized if the line size of the suction line is increased by one size. Refer to the installation section (p.5) for recommended suction plumbing recommendations.

What to Check: • Blocked air exhaust muffler.Corrective Action: • Remove muffler, clean or de-ice and reinstall.

What to Check: • Excessive Suction Lift.Corrective Action: • For lifts exceeding 20 feet (6 meters), filling the pump chambers with liquid will prime the pump in most cases. If not, place pump closer to fluid level.

What to Check: • Suction line cavitation.Corrective Action: • If no obstructions are in the suction line of the pump, decrease the inlet air pressure and/or volume to the pump. This will slow down the diaphragm speed and reduce the cavitation.

What to Check: • Partially blocked exhaust muffler.Corrective Action: • Remove muffler and make sure that some of the material being pumped has not migrated into the muffler element. If it has, replace the element or clean it and reinstall. If product has made it to the muffler, then the diaphragm assembly will need to be inspected. Refer to the Diaphragm Replacement section (p.15).

What to Check: • Suction side air leakage or air in the product.Corrective Action: • Visually inspect all suction side gaskets, seals, as well as pipe and pipe connections.

PUMP CYCLE SEEMS UNBALANCED OR PRODUCES EXCESSIVE VIBRATION

What to Check: • Excessive flooded suction in system.Corrective Action: • Check height of fluid above pump. For flooded conditions, exceeding 10 feet (3 meters) of liquid, install a back pressure device in the exhaust side of the pump.

What to Check: • Worn or misaligned check valve or check valve seat.Corrective Action: • Disassemble the wet end of the pump and inspect check valves and seats for wear and proper seating. Replace them if necessary. Refer to the Check Valve section (p.15) for disassembly instructions.

What to Check: • Obstructed check valves.Corrective Action: • Disassemble the wet end of the pump and look for obstructions that may prevent the check valve from seating on the seat. Look for damage on the valve and the seat. Replace them as necessary. Refer to the Check Valve section for disassembly (p.15).

What to Check: • Rigid pipe connections.Corrective Action: • Install flexible pipe isolators or expansion joints between the plumbing and the pump.

What to Check: • Pulsation in the discharge line.Corrective Action: • Excessive pulsation in the discharge line may be corrected by installing a Warren Rupp Tranquilizer Surge Suppressor.


Caution! Whenever troubleshooting or performing any repairs on any IDEX AODD equipment, always remove air supply line to the pump and wear proper personal protective equipment.

LED OUTPUT FOR AirVantage UNIT

STATE LED OUTPUTStartup/Settle/Deadhead SolidStandby/Low Flow 1 Second ON / 1 Second OFFLearn Mode 0.1 Seconds ON / 0.1 Seconds OFFSeek/Optimize 1 Second ON / 0.1 Seconds OFFSteady State/Air Savings OFF / ON in rhythm with Cycle Rate of Pump

AirVantage LED DOES NOT LIGHT UP AT ALLWhat to Check: • Make sure power switch on the control module is turned on, (depressed to the left) • Make sure air is being supplied to pump or make sure 110 VAC unit has power being supplied to itCorrective Action:• Cycle power switch off/on • Unplug patch cable and cycle power switch off/on • Consult Factory After Sales Support team

AirVantage LED LIGHTS UP AND STAYS ON SOLID

What to Check: • Make sure patch cable is plugged in and lockedCorrective Action: • Consult Factory After Sales Support team

VALVE FIRES ONCE AND IMMEDIATELY RESETSCorrective Action: • Consult Factory After Sales Support team

AirVantage TroubleshootingVALVE LED NEVER LEAVES SEEK MODE - AirVantage LED PULSING IN TIME TO PUMP, BUT VALVE NOT ACTUATING AND THE PUMP IS NOT SAVING AIR

Corrective Action: • Consult Factory After Sales Support team

UNEXPECTED OPERATING CONDITION (AIR SAVINGS OR FLOW RATE)What to Check: • Check for varying environmental pumping conditions (changing head or suction) • Check ice buildup in exhaust area • Inspect sleeve and spool set for damageCorrective Action: • Consult Factory After Sales Support team

PUMP CYCLING IS UNSTABLE OR ERRATICWhat to Check: • Run pump without AirVantage and check pump operation • Make sure pump has correct sleeve and spool set installed • Make sure patch cable plug is connected and locked • Make sure power wire connectors are tightCorrective Action: • Consult Factory After Sales Support team

PUMP RUNNING SLOWLYWhat to Check: • Run pump without AirVantage and check operation • Cycle the power off/on to the control module to reset controller • Check ice buildup in exhaust area • Inspect sleeve and spool set for damageCorrective Action: • Consult Factory After Sales Support team • Cycle the power switch on the control module off/on


AirVantage Troubleshooting ContinuedAirVantage RESETS AND ENTERS LEARN MODE TOO FREQUENTLY

What to Check: • Check for excessive varying environmental pumping conditions (changing head or suction) • Check ice buildup in exhaust area • Inspect sleeve and spool set for damage • Make sure patch cable plug is connected and lockedCorrective Action: • Consult Factory After Sales Support Team

PUMP STALLS, RESETS, LEARNS, SEEKS AND REPEATSWhat to Check: • Make sure patch cable plug is connected and locked • Check ice buildup in exhaust areaCorrective Action: • Consult Factory After Sales Support Team

PUMP MOVES OUT OF STEADY STATE AND NEVER ATTEMPTS TO RELEARN (LED ON)

What to Check: • Make sure patch cable plug is connected and locked • Cycle the power off/on to the control moduleCorrective Action: • Consult Factory After Sales Support Team • Cycle the power switch on the control module off/on

WHAT TO DO IN THE EVENT OF A DIAPHRAGM FAILUREIf a diaphragm failure has been detected in pumps fitted with AirVantage, see page 5 for shut-down procedure.What to Check: • Has product migrated to the sensor?Corrective Action: • If the sensor has been submerged in product, the sensor will need to be replaced. Consult the AirVantage servicing section of the manual for detailed instructions.

What to Check: • Has product contaminated the check valve cartridge?Correct Action: • If a significant amount of product has made it into the check valve assembly, then the unit will need to be dis-assembled for inspection. If the check valve assembly is damaged, then it will need to be replaced. Consult parts list for information.

SEAL, O-RING

(Purchased Separately)

VALVE, POPPET

VALVE, SOLENOID

CAPSCREW, HEX SOC HD, 10-32 X .50

COVER

SEAL, O-RING

SEAL, O-RING

MUFFLER

SEAL, O-RING

ASSEMBLY, POWER GENERATOR

CAPSCREW, HEX SOC HD, 10-32 X 2.25

CAPSCREW, HEX SOC HD, 10-32 X 1.00

CAPSCREW, HEX SOC HD, 10-32 X .50

O-RING

O-RING

CONTROL MODULE

REGULATOR

Optional 1/4" NPT Pipe Plug (P/N 618.011.330)Must be installed if performing direct spraywash-down of pump


Composite Repair Parts ListItem Part Number Description Qty1 031.019.004 Ass’y - Air Valve 1 031.098.001 Ass’y - Air Valve (Pulse Output Application) 12 032.058.000 Ass’y - AirVantage 13 070.006.170 Bearing 24 095.073.001 Pilot Valve Assembly 15 114.032.156 F Intermediate 16 115.158.080 Bracket, Leg 27 115.159.080 Bracket, Leg 28 115.172.159 Bracket, Mounting, R.H. 19 115.173.159 Bracket, Mounting, L.H. 110 132.002.360 Bumper, Diaphragm Plate 211 135.016.162 Bushing, Threaded, W/ O-Ring 560.001.360 212 165.138.150 Cap, End, Sensor 113 170.024.330 Capscrew, Hex Hd, 7/16-14 X 1 814 170.026.330 Capscrew, Hex Head 3/8-16 X 3 1/2 215 170.031.330 Capscrew, Hex Hd, 7/16-14 X 2.50 416 170.035.330 Capscrew, Hex Hd, 7/16-14 X 2 817 170.045.330 Capscrew, Hex Head 5/16-18 X 1 1/4 418 170.052.330 Capscrew, Hex Head 3/8-16 X 2 1/2 219 170.060.330 Capscrew, Hex Hd, 7/16-14 X 1 1/2 820 170.061.330 Capscrew, Hex Head 3/8-16 X 2 1621 170.121.330 Capscrew, Hex Head 5/16-18 X 5 1/2 422 171.002.330 Capscrew, Socket Head 2 171.002.110 Capscrew, Socket Head (Stainless Steel Only) 223 171.100.115 Capscrew, Hex Head 5/16-18 X 2.50 424 196.001.157 Chamber, Inner 225 196.002.010 NS Chamber, Outer 2 196.002.110 NS Chamber, Outer 2 196.002.157 NS Chamber, Outer 226 258.023.147 Cover, Sensor 127 286.007.354 Diaphragm 2 286.007.356 Diaphragm 2 286.007.360 Diaphragm 2 286.007.363 Diaphragm 2 286.007.364 Diaphragm 2 286.007.365 Diaphragm 2 286.007.366 Diaphragm 228 312.012.010 Elbow Suction 2 312.012.110 Elbow Suction 2 312.012.156 Elbow Suction 229 312.013.010 Elbow, Discharge 2 312.013.110 Elbow, Discharge 2 312.013.156 Elbow, Discharge 230 338.005.360 Flap Valve 4 338.005.363 Flap Valve 4 338.005.364 Flap Valve 4 338.005.365 Flap Valve 4 338.005.366 Flap Valve 4 338.010.354 Flap Valve 4 338.010.356 Flap Valve 4 338.010.357 Flap Valve 431 360.041.379 Gasket, Pilot Valve 132 360.048.425 Gasket, Main Air Valve 133 518.001.010 Manifold 2 518.001.110 Manifold 2 518.001.157 Manifold 2

Item Part Number Description Qty34 530.041.000 Muffler 135 538.108.110 Nipple, Pipe 136 545.007.330 Nut, Hex - 7/16-14 837 547.002.110 Nut, Stop 838 560.001.360 O-Ring 239 560.011.360 O-Ring 240 560.022.360 O-Ring 241 560.033.360 O-Ring 242 560.046.360 O-Ring (Stainless Steel Units Only) 243 560.200.360 O-Ring 144 560.201.360 O-Ring 245 560.203.360 O-Ring 246 570.001.360 Pad, Hinge-Flap Valve 4 570.001.363 Pad, Hinge-Flap Valve 4 570.001.364 Pad, Hinge-Flap Valve 4 570.001.365 Pad, Hinge-Flap Valve 4 570.001.366 Pad, Hinge-Flap Valve 447 570.009.360 Pad, Wear 2 570.009.363 Pad, Wear 2 570.009.364 Pad, Wear 2 570.009.365 Pad, Wear 248 612.047.330 Plate, Inner Diaphragm 249 612.008.330 Plate, Outer Diaphragm 2 612.096.110 Plate, Outer Diaphragm (SST Units Only) 250 612.241.147 Plate, Adapter 151 618.003.330 Plug, Pipe, 1/4 452 618.003.330 Plug, Pipe, 1/4 2 618.003.110 Plug, Pipe, 1/4 (Stainless Steel Only) 253 620.011.114 Plunger, Actuator 254 670.005.110 Retainer, Flap Valve 455 675.013.360 Ring, Sealing 4 675.013.363 Ring, Sealing 4 675.013.364 Ring, Sealing 4 675.013.365 Ring, Sealing 4 675.013.366 Ring, Sealing 456 685.007.120 Rod, Diaphragm 157 720.004.360 Seal, U-Cup 258 722.070.360 Seat, Flap Valve 4 722.070.363 Seat, Flap Valve 4 722.070.364 Seat, Flap Valve 4 722.070.365 Seat, Flap Valve 459 724.008.000 Sensor, Feed Back 160 770.005.330 Spacer (Aluminum Only) 261 770.074.159 Spacer 462 807.018.110 Stud, 1/4-20 863 846.001.167 Probe Tip 264 894.014.000 Valve, Check 164a 031.206.000 Cartridge, Check Valve 165 900.005.330 Washer, Lock, 3/8 2066 900.006.330 Washer, Lock - 7/16 (Aluminum) 1667 901.022.330 Washer, Flat, 7/16 868 902.003.000 Washer, Sealing 269 P126-0011 Foam Bumper, Sensor 270 P126-0032 Capscrew, Socket Head, 8/32 x 7/16 8


Composite Repair Parts KitsAvailable Service And Conversion Kits Air End Kit - 476.247.162 Seals, O-rings, Gaskets, Air Valve Sleeve and Spool Set, and Pilot Valve AssemblyWet End Kit – 476.270.356 (RHDF2, HDF2) Hytrel Diaphragms, Flap Valves and Neoprene Hinge Pads, Wear Pads, Sealing RingsWet End Kit – 476.270.360 (RHDF2, HDF2) Nitrile Diaphragms, Flap Valves, Hinge Pads, Wear Pads, and Sealing RingsWet End Kit – 476.270.364 (RHDF2, HDF2) EPDM Diaphragms, Flap Valves, Hinge Pads, Wear Pads, and Sealing RingsWet End Kit – 476.270.365 (RHDF2, HDF2) Neoprene Diaphragms, Flap Valves, Hinge Pads, Wear Pads, and Sealing RingsWet End Kit – 476.270.632 (RHDF2, HDF2) Neoprene Diaphragms, Hinge Pads, Wear Pads, and Sealing Rings, and Hytrel Flap ValvesWet End Kit – 476.270.643 (RHDF2, HDF2) Santoprene Diaphragms, Flap Valves and EPDM Hinge Pads, Wear Pads, Sealing Rings Sensor Kit - 476.306.000 (Sensor, Probe Tips and O-rings)Poppet Valve Kit (Poppet Valve Assembly, O-ring)Poppet Valve Assembly Kit (Poppet Valve Assembly, O-ring, Regulator and Pilot Valve)Control Module Kit – 476.302.000 (Power Gen AirVantage Only) (Control Module Assembly, Gaskets, Hardware and O-rings)Power Gen Kit – 476.293.000 (Power Gen AirVantage Only) (Power Gen, Gasket, Hardware and O-ring)Seal Kit – 476.280.000 O-rings and GasketsProbe Tip Kit – 476.283.000 (Probe Tips and O-rings)Midsection Upgrade Kit – 475.XXX.000 Consult Factory (Replaces S20 Metallic Midsection with AirVantage Components)Electronic Leak Detector Kits 032.037.000 100-120/220-240 VAC 032.045.000 12-32 VDC

RING, SEALING

PAD, HINGE

FLAP VALVE

DIAPHRAGM

PAD, WEAR

WETTED END KIT

GASKET, AIR VALVE

BUMBER, AIR VALVE

GASKET, MAIN AIR VALVE

PILOT VALVE

PLUNGER, ACTUATOR

BUSHING

SEAL, U-CUP

O-RING

O-RING

GASKET, PILOT VAVLVE

AIR END KIT


Composite Repair Parts Drawing: Wetted Side

Note: Refer to Composite Repair Parts List on page 12 for part numbers

20

18

55

33

37

54

46

5830

5437

58 3046

6065

14

55

1562

62

16

7

61

21

64

55

65

6520

25

29

28

36

6534

52

52

6

39

50

35

23

39

43

9

8

2

67

64a

PROBE TIP

O-RING

SENSOR, FEED BACK

Page 14


Read these instructions complete ly, before installation and start-up. It is the responsibility of the purchaser to retain

this manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.

IMPORTANT

FLAP VALVE SERVICINGValve inspection requires removal of 3/8" hex nuts and elbows. When the top suction elbows are removed, the valve and seat are connected as an assembly. When the bottom discharge elbows are removed, the valve and seat stay with the outer chamber. Visual inspection and cleaning is possible. If parts are to be replaced, remove the self-locking nuts and all parts are accessible.

DIAPHRAGM SERVICINGDiaphragms can be inspected or the diaphragm assembly removed without removing the suction and discharge flanges. Remove (8) nuts around the chamber flange, and the housing assembly will pull off. Flap valves can be inspected for proper seating at this point as well as the diaphragm. Use care to keep foreign matter from behind the diaphragm. The opposite diaphragm may be inspected by the same procedure. If either diaphragm has to be replaced, follow closely these steps: Pull the outer diameter of one diaphragm off the (8) capscrews. NOTE: One side only! On the free diaphragm assembly, use a 3/8" allen wrench to turn the assembly (diaphragm, plates and screw) loose from the shaft. Once the assembly has turned, it will turn out by hand by use of the diaphragm. Now the opposite diaphragm assembly and the drive shaft will pull free from the capscrews and pump intermediate assembly. The interior components consisting of sleeve bearings, rod seals, and pilot valve actuator bushings are now accessible for service if required. Hold the shaft in a clamping device making sure to protect surface of shaft so as not to scratch or mar it in any way. The diaphragm assembly will turn loose. To disassemble the components, turn a 1/4"-20 capscrew by hand into the tapped hole in the inner plate. This keeps the plate from turning while the socket head capscrew is removed. To do this, place assembly in a vise so the two protruding ends of screws are loose in the vise jaws (about 3/4" apart). Turn the center screw loose from the back plate and the assembly will come apart.

“AirVantage CAUTION” – If product is observed on the air side of the diaphragm, refer to the “Air-Vantage Servicing” section of the service manual.

REASSEMBLY All procedures for reassembling the pump are the reverse of the previous instructions with further instructions as shown:

1. The diaphragm assemblies are to be installed with the natural bulge outward or toward the head of the center screw. Make sure both plates are installed with outer radii against the diaphragm. After all components are in position in a vise and hand tight, set a torque wrench for 480 inch pounds (40 ft. pounds) (54.23 Newton meters) or, 600 inch pounds (50 ft. pounds) (67.79 Newton meters) for Santoprene, using a (3/8") allen head socket. After each diaphragm sub assembly has been completed, thread one assembly into the shaft (held near the middle in a vise having soft jaws to protect the finish) making sure the stainless steel washer is in place on the capscrew. Make sure 1/4"-20 mounting screw has been removed and that the bumper (Item #19 on drawing) is in place in the shaft. Install this sub assembly into the pump and secure by placing the outer chamber housing and capscrews on the end with the diaphragm. This will hold the assembly in place while the opposite side is installed. Make sure the last diaphragm assembly is torqued to 30 ft. lbs. (40.67 Newton meters) before placing the outer diaphragm over the capscrews. If the holes in the diaphragm flange do not line up with

the holes in the chamber flange, turn the diaphragm assembly in the direction of tightening to align the holes so that the capscrews can be inserted. This final torquing of the last diaphragm assembly will lock the two diaphragm assemblies together. Place remaining outer chamber on the open end and tighten down the securing nuts gradually and evenly on both sides. Caution should be used while reassembling Flap valves. The valves are designed for some preload over the retainer hinge pad. This is done to insure proper face contact with the seat. After all parts are in place, tighten the lock nuts down on the assembly to the point where visual inspection shows that seat and valve face mate without gap. This is important for dry prime. However, after priming action has started, valves will function due to differential pressure without concern or trouble.

PILOT VALVE The pilot valve assembly is accessed by removing the main air distribution valve body from the pump and lifting the pilot valve body out of the intermediate housing. Most problems with the pilot valve can be corrected by replacing the o-rings. Always grease the spool prior to inserting it into the sleeve. If the sleeve is removed from the body, reinsertion must be at the chamfered side. Grease the o-rings to slide the sleeve into the valve body. Securely insert the retaining ring around the sleeve. When reinserting the pilot valve, push both plungers (located inside the intermediate bracket) out of the path of the pilot valve spool ends to avoid damage.

PILOT VALVE ACTUATOR Bushings for the pilot valve actuators are threaded into the intermediate bracket from the outside. The plunger may be removed for inspection or replacement. First remove the air distribution valve body and the pilot valve body from the pump. The plungers can be located by looking into the intermediate. It may be necessary to use a fine piece of wire to pull them out. The bushing can be turned out through the inner chamber by removing the outer chamber assembly. Replace the bushings if pinshave bent.


Composite Repair Parts Drawing: Air Side

Note: Refer to Composite Parts List on page 12 for part numbers

6613

56

4024

27

4868

10

5111

3853

57

1

32

4

31

4749

22

4463

42

5

70

2670

3

1245

4169

59

Page 16


INTERMEDIATE AND AirVantage SENSOR SERVICING• To service the intermediate and AirVantage sensor, first shut off and bleed the air being supplied to the

pump. For safety purposes, the air supply line should be disconnected from the pump. Shut off both the suction and discharge lines to the pump. Consult the “Composite Repair Parts Drawing”.

Step #1: Remove the Patch Cable• Twist the ribbed portion of the patch cable connector in a counterclockwise direction, until it unthreads

from the connector. The cable can either be removed from the intermediate or from the control module.

Step #2: Remove the AirVantage from the Pump• Use a ½” socket and remove the four 5/16-18 x 5 cap screws that hold the AirVantage to the pump. Be

sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on the plastic cover located on the bottom.

Step #3: Remove the Manifolds, Chambers, and Diaphragms (See Diaphragm Servicing Section)

Step #4: Remove the Diaphragm Assemblies• Refer to the “Diaphragm Servicing” section of the manual to remove diaphragm assembly from the

pump. • “AirVantage CAUTION” – When the diaphragm assembly is removed, watch for the brass probe

tips located on the end of the sensor rod. There is one brass probe tip and one o-ring per side. Inspect the probe tips and o-rings for wear. For every diaphragm service, these parts should be replaced and are available in kit form. Consult the “Composite Repair Parts Drawing” for part numbers and quantities.

Step #5: Remove the End Caps• Use an Allen wrench and remove the two screws from the End Caps on either side of the intermediate.• Use two small flat-head screw drivers to simultaneously pry the End Caps up at the ends.• “AirVantage CAUTION” – Remove the End Caps from the intermediate with caution, taking care

not to damage the sensor. Inspect the gaskets and u-cup seals under each End Cap and replace them as necessary.

Step #6: Accessing the Actuator Plunger Bushings and O-rings• The actuator plunger pin bushings and o-rings can now be accessed. If it is determined that these parts

need to be replaced, use a small screwdriver and remove the retaining rings. • NOTE: It is recommended that new retaining rings be installed after disassembly. The bushing

and o-ring can now be removed and inspected.

Step #7: Accessing the AirVantage Sensor• If the sensor needs to be replaced, use a 13/16” socket and remove the plastic nut securing the

connector to the intermediate. Slide the connector out of the hole, taking care not to lose/misplace the gasket on the connector.

• The sensor can now be removed from the intermediate assembly.

Step#8: Reinstallation• Slide the new sensor assembly in the intermediate. • “AirVantage CAUTION” – Make sure the cable assembly fits into the groove machined in the

intermediate. Failure to do so may damage the cable during assembly.

• Feed the connector through the hole in the intermediate, making sure the gasket is on the connector before installation. The flat edge on the connector should line up with the inside of the intermediate. Install the nut and hand tighten it using a 13/16" socket.

• The inner chambers and gaskets can now be reinstalled. Use blue thread locker on the inner chamber bolts and torque them to 300 in-lbs.

• Refer to the “Diaphragm Servicing” section of the manual to finish the diaphragm installation procedure.

Page 17

PROBE TIP

O-RING

SENSOR, FEED BACK

WASHER, SEALING

PLATE, DIAPHRAGM

DIAPHRAGM

PAD, WEAR

PLATE,OUTER DIAPHRAGM

CAPSCREW

SENSOR COVER

CAPSCREW

END CAP

FEED BACK SENSOR

O-RING

CAPSCREW

INTERMEDIATE

JAM NUT

O-RING

FOAM BUMPER

BEARING

SEAL


A

BRACKET, INTERMEDIATE, ASSEMBLYSENSOR, FEEDBACK

NUT

SEAL

DIAPHRAGM


PLATE,INNER DIAPHRAGM

PROBE TIP

O-RING

SENSOR, FEEDBACK

BUMPER

DETAIL A

FLAT EDGE


Air Valve Servicing, Assembly Drawing & Parts List

AIR DISTRIBUTION VALVE SERVICINGTo service the air valve, first shut off the compressed air, bleed pressure from the pump, and disconnect

the air supply line from the pump. Step #1:

• Using a 9/16" wrench or socket, remove the four hex capscrews. Remove the air valve assembly from the pump.

• Remove and inspect gasket for cracks or damage. Replace gasket if needed. Step #2: Disassembly of the air valve.

• Using a 7/16" wrench or socket, remove the eight hex capscrews that fasten the end caps to the valve body. Next, remove the two end caps. Inspect the two o-rings on each end cap for damage or wear. Replace the bumpers as needed.

• Remove the bumpers. Inspect the bumpers for damage or wear. Replace the bumpers as needed.• Remove the spool from the sleeve. Be careful not to scratch or damage the outer diameter of the spool.

Wipe spool with a soft cloth and inspect for scratches or wear.• Inspect the inner diameter of the sleeve for dirt, scratches, or other contaminants. Remove the sleeve if

needed and replace with a new sleeve and spool set.

Step #3: Reassembly of the air valve.

• Install one bumper and one end cap, with two o-rings, and fasten with four hex capscrews to the valve body.

• Remove the new sleeve and spool set from the plastic bag. Carefully remove the spool from the sleeve. Install the six o-rings into the six grooves on the sleeve. Apply a light coating of grease to the o-rings before installing the sleeve into the valve body, align the slots in the sleeve with the slots in the valve body. Insert the spool into the sleeve. Be careful not to scratch or damage the spool during installation. Carefully insert the sleeve into the bumper and end cap (with o-rings) and fasten with the remaining hex capscrews.

• Fasten the air valve assembly and gasket to the pump. Connect the compressed air line to the pump. The pump is now ready for operation.

Read these instructions completely, before i n s t a l l a t i o n a n d star t -up . I t is the responsibility of the purchaser to retain this

manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.

IMPORTANT

AIR VALVE ASSEMBLY PARTS LIST Item Part Number Description Qty1 031-183-003 Air Valve Assembly 11-A 031.012.162 Sleeve and Spool Set 11-B 095.043.156 Description 11-C 132-014.358 Bumper, Air Valve 21-D 165.011.157 Cap, End 21-E 170.032.330 Capscrew, Hex Head 1/4-20 x 3/4 81-F 360.010.427 Body, Air Valve 2 1-F 560.020.360 O-ring 6

1.B

1.A1.A

1.C

1.F

1.D1.E

1.F

1.C1.F

1.D

Note to Trent: Do not paste this table in S/M. Only use to modify on on page 18

Page 18

ITEM NO. PART NUMBER DESCRIPTION QTY.

1.A 031.012.162 SLEEVE & SPOOL SET 1

1.B 095.043.156 DESCRIPTION 1

1.C 132.014.358 BUMBER, AIR VALVE 2

1.D 165.011.157 CAP, END 2

1.E 170.032.330 CAPSCREW, HEX HEAD 1/4-20 X 3/4 8

1.F 360.010.427 BODY, AIR VALVE 2

1.F 560.020.360 O-RING 6


Air Valve with Stroke Indicator Assembly Drawing and Parts List

Air Distribution Valve With Stroke Indicator Option ServicingTo service the air valve first shut off the compressed air supply, bleed the pressure from the pump, and

disconnect the air supply line from the pump. Step #1: See COMPOSITE REPAIR PARTS DRAWING.

• Using a 5/16" Allen wrench, remove the four hex socket capscrews and four flat washers. Remove the air valve assembly from the pump.

• Remove and inspect gasket for cracks or damage. Replace gasket if needed. Step #2: Disassembly of the air valve.

• To access the internal air valve components first remove the two retaining rings from each end of the air valve assembly using clip ring pliers.

• Next remove the two end caps. Inspect the o-ring for cuts or wear. Replace the o-rings if necessary.

• Remove the two bumpers. Inspect the bumpers for cuts, wear or abrasion. Replace if necessary.• Remove the spool from the sleeve. Be careful not to scratch or damage the outer diameter of the spool.

Wipe spool with a soft cloth and inspect for scratches or wear.• Inspect the inner diameter of the sleeve for dirt, scratches, or other contaminants. Remove the sleeve if

needed and replace with a new sleeve and spool set.

Step #3: Reassembly of the air valve.• Install one bumper and one end cap with o-rings into one end of the air valve body. Install one retaining

ring, into the groove on the same end. Insert the safety clip through the smaller unthreaded hole in the endcap.

• Remove the new sleeve and spool set from the plastic bag. Carefully remove the spool from the sleeve. Install the six o-rings into the six grooves on the sleeve. Apply a light coating of grease to the o-rings before installing the sleeve into the valve body. Align the slots in the sleeve with the slots in the valve body. Insert the spool into the sleeve. Be careful not to scratch or damage the spool during installation. Push the spool in until the pin touches the safety clip on the opposite end.

• Install the remaining bumper, end cap with o-rings and retaining ring.

• Fasten the air valve assembly and gasket to the pump.

• Connect the compressed air line to the pump. Remove the safety clip. The pump is now ready for operation.

Read these instructions completely, before i n s t a l l a t i o n a n d star t -up . I t is the responsibility of the purchaser to retain this

manual for reference. Failure to comply with the recommendations stated in this manual will damage the pump, and void factory warranty.

IMPORTANT

AIR VALVE ASSEMBLY PARTS LIST

Item Part Number Description Qty1 031-147-003 Air Valve Assembly 11-A 031-012.162 Sleeve and Spool Set 11-B 095-043.156 Description 11-C 132-014.358 Bumper, Air Valve 21-D 165-065.010 Cap, End 21-E 170.032.330 Capscrew, Hex Head 1/4-20 x 3/4 81-F 360.010.427 Body, Air Valve 21-F 560.020.360 O-Ring 61-G 210-008-330 Clip, Safety 11-H 560-029-360 O-Ring 2

1.D1.F

1.C

1.A1.A

1.F

1.B

1.G

1.D

1.E

Page 19

1.H

Note to Trent: Do not paste this table in S/M. Only use to modify on on page 19


To service the pilot valve or the actuator plungers, first shut off and bleed the air being supplied to the pump. For safety purposes the air supply line should be disconnected from the pump. Then shut off the suction and discharge lines to the pump. Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump.

Step #1: Remove the Patch Cable• Twist the ribbed portion of the patch cable connector in a counterclockwise

direction, until it unthreads from the connector. The cable can either be removed from the intermediate or from the control module.

Step #2: Remove the AirVantage from the Pump• Use a ½” socket and remove the four 5/16-18 x 5 cap screws that hold the AirVantage to the

pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, carefully set the unit down on the plastic cover located on the bottom.

Step #3: Remove the Air Inlet Adapter Plate Adapter• Use a ¼” hex key wrench and remove the four 5/16-18 x 1 ¼ socket head cap screws. This will allow

access to the pilot valve, gaskets and actuator plungers.

Step #4: Disassemble the Pilot Valve• Remove the pilot spool and wipe it clean. Inspect the spool and o-rings for dirt, cuts or wear.

Replace parts if necessary.• Use a set of outside snap ring pliers and remove the retaining ring holding the sleeve in the pilot

valve body. Gently push the sleeve from the body and wipe it clean. Inspect the sleeve and o-rings. Replace parts if necessary.

Step #5: Reassemble the Pilot Valve• Generously lubricate the o-rings on the pilot sleeve with multipurpose grease

(BP-LSEP-2 or equivalent). Carefully insert the sleeve in the pilot valve body, taking care not to shear any of the o-rings. Install the retaining ring.

• Generously lubricate the o-rings on the pilot spool. Carefully insert the spool in the• sleeve.

Step #6: Inspect the Actuator Plungers• With the pilot valve assembly off the pump, the actuator plungers can be accessed.• Remove the plungers and inspect them for nicks or unusual wear. Replace them if necessary. If the

bushings or o-rings need to be replaced, refer to the Intermediate Servicing section (p.17). Apply a generous amount of lubricant and install the plungers back in the intermediate. Push the as far in as they will go.

Step #7: Reassembly• Reinstall the pilot valve and gaskets. Take caution during the installation to align the ends of the pilot valve

stem between the plunger pins. If the pilot valve does not fit flush against the gasket, check to make sure the actuator plunger are pushed all the way. Failure to do so may cause damage to the pilot valve or the actuators.

Step #8: Reassemble AirVantage and Cable• Reinstall the AirVantage using the four 5/16-18 x 5 cap screws and torque to 90 in-lbs.• Reattach the patch cable connector that connects the AirVantage module to the intermediate.

Pilot Valve and Actuator Plunger Servicing


15

1

29

4.F

4.A

4.B

4.D

49

35

10

28

4.C

4.E

5

Item Part Number Description Qty4.A 095.070.558 BODY, PILOT VALVE 1 4.B 755.025.162 SLEEVE, PILOT VALVE 14.C 560.033.360 O-RING 44.D 775.026.115 SPOOL, PILOT VALVE 14.E 560.023.360 O-RING 24.F 675.037.080 RING, RETAINING 1


PULSE OUTPUT KIT OPTIONThis pump can be fitted with a Pulse Output Kit. This converts the mechanical strokes of the

pump to an electrical signal which interfaces with the Stroke Counter/ Batch Controller or user control devices such as a PLC.

The Pulse Output Kits mount directly onto the Muffler Cap on the Air Distribution Valve Assembly or onto the air valve and senses each stroke of the main spool.

Consult the factory for further information and availability.

Pulse Output Kit Drawing

Pulse Output Kits475-244-001 10-30 VDC

475-244-002 110/220 VAC

475-244-003 10-30VDC, 110VAC and 220 VAC




Composite Repair Parts Drawing: AirVantage Unit

1

2

3

4

5

3

3

7

6

3

6

8

1

9

10

13

12

10

14

15

16

17

18

20

19

11

ITEM No. PART NUMBER DESCRIPTION QTY.,WERCSPAC1 HEX SOC HD, M6-1.0 x 35 8

1REVOC000.020.85223 720.004.360 SEAL, O-RING 44 765.004.000 VALVE, SOLENOID 15 893.104.000 VALVE, POPPET 1

,WERCSPAC6 HEX SOC HD, M6-1.0 x 25 8REWOP7 GENERATION MODULE 1

8 258.019.000 COVER, END 19 020.069.000 REGULATOR 1

10 560.200.360 SEAL, O-RING 2LORTNOC11 MODULE 1

,LAES21 O-RING 113 165.135.330 CAP, SWITCH 1

141,PAC51 DUST 1,EVLAV61 DUST 1

,WERCSPAC71 HEX SOC HD, 5-40 x .25 1,LAES81 O-RING 1

,ROTSERRA91 SPARK 1,ETALP02 PERFORATED 1

171.092.115

171.091.115031.202.000

249.019.000560.104.360

675.067.115

, RS20

430.050.147720.073.365171.093.115560.205.360530.045.115165.137.115

RING, RETAINING

21 901.051.115 WASHER, FLAT, M6 8

1

2

3

4

5

3

3

7

6

3

6

8

1

9

10

13

12

10

14

15

16

17

18

20

19

11

ITEM No. PART NUMBER DESCRIPTION QTY.,WERCSPAC1 HEX SOC HD, M6-1.0 x 35 8

1REVOC000.020.85223 720.004.360 SEAL, O-RING 44 765.004.000 VALVE, SOLENOID 15 893.104.000 VALVE, POPPET 1

,WERCSPAC6 HEX SOC HD, M6-1.0 x 25 8REWOP7 GENERATION MODULE 1

8 258.019.000 COVER, END 19 020.069.000 REGULATOR 1

10 560.200.360 SEAL, O-RING 211

,LAES21 O-RING 113 165.135.330 CAP, SWITCH 1

141,PAC51 DUST 1,EVLAV61 DUST 1

,WERCSPAC71 HEX SOC HD, 5-40 x .25 1,LAES81 O-RING 1

,ROTSERRA91 SPARK 1,ETALP02 PERFORATED 1

171.092.115

171.091.115031.202.000

249.028.000560.104.360

675.067.115

LORTNOC MODULE, RHDF2 Hazardous Duty

430.050.147720.073.365171.093.115560.205.360530.045.115165.137.115

RING, RETAINING

1



CAPSCREW, HEX SOC HDM5 x 0.8 x 16

COVER

SEAL, O-RING

CONNECTOR(To solenoid)

REGULATOR

VALVE, SOLENOID

VALVE, POPPET

CONNECTOR/CABLE(To Intermediate)

CAP, SWITCH

O-RING

AirVantage Servicing -Pilot Valve and Pressure RegulatorPilot Valve and Pressure Regulator To service the pilot valve or the pressure regulator, first shut off and bleed the air being supplied to the pump. For safety purposes the air supply line should be disconnected from the pump. Then shut off the suction and discharge lines to the pump. Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump. During the servicing of the AirVantage, consult the “AirVantage Composite Repair Parts Drawing”.


from the connector. The cable can be removed only from the intermediate.

Step #2: Remove the AirVantage from the Pump• Use a ½” socket and remove the four 5/16-18 x 5 ½ cap screws that hold the AirVantage to the pump.

Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on the plastic cover located on the bottom. Inspect the o-ring between the poppet valve and the adapter plate for damage.

Step #3: Access the Pilot Valve and Pressure Regulator• Use a 4mm hex-key wrench and remove the four M5 x 16mm socket head cap screws securing the top

cover on. Lift the cover off, exposing the pilot valve and pressure regulator. There is a molded o-ring seal located on the underside of the cap. Make sure the o-ring stays located within the groove.

• If the pilot valve needs to be replaced, unplug the connector attached to it. Use a miniature 4-way Phillips screwdriver and remove the two screws holding the pilot valve to the plate. The valve and gasket can now be removed and/replaced. When reinstalling the pilot valve, tighten the screws to snug with a miniature 4-way Phillips screwdriver.

• “AirVantage CAUTION” – Be sure to reattach the connector to the pilot valve.• If the pressure regulator needs to be replaced, use slip-joint pliers to unscrew the regulator from the

body by turning it in a counterclockwise direction. • “AirVantage CAUTION” – Do not loosen or tighten the regulator by turning the knurled portion

of the unit. Place the slip-joint pliers on the smooth area underneath the knurled area of the regulator.

Step #4: Reinstallation• Reinstall the top cover, making sure the o-ring seal is still in the groove. Tighten the four M5 screws.• Reinstall the AirVantage using the four 5/16-18 x 5 ½ cap screws and torque to 90 in-lbs.• “AirVantage CAUTION” – Be sure to reattach the patch cable connector that connects the

AirVantage module to the intermediate.



AirVantage Servicing - Power Generation Module To service the power generation module, first shut off and bleed the air being supplied to the pump. For safety purposes the air supply line should be disconnected from the pump. Then shut off the suction and discharge lines to the pump. Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump. During the servicing of the AirVantage, consult the “AirVantage Composite Repair Parts Drawing”.


from the connector. The cable can be removed only from the intermediate.

Step #2: Remove the AirVantage from the Pump• Use a ½” socket and remove the four 5/16-18 x 5 ½ cap screws that hold the AirVantage to the

pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on the plastic cover located on the top of the unit. Inspect the o-ring between the poppet valve and the adapter plate for damage.

Step #3: Access the Power Generation Module• Use a 4mm hex-key wrench and loosen the four M5 x 16mm socket head cap screws• securing the bottom cover. Lift the bottom cover off, exposing the power generation module. There is

a molded o-ring seal located on the underside of the cap. Make sure the o-ring stays located within the groove.

• If the power generation module needs to be replaced, unplug the connector that connects• the power generator to the control board. Use a 4mm hex-key wrench to loosen the four M5 x 25mm

socket head cap screws. The power generation module should now be loose. Carefully lift the power generation module off the rest of the assembly, making sure that the control board wire and connector slips through the hole in the power generation case.

• "AirVantage CAUTION" - Take caution not to loosen the o-ring that seals between the components.

Step #4: Reinstallation• When reinstalling the new module make sure to feed the control module wire through the hole in the

power generation case. Install the four M5 x 25mm socket head cap screws and tighten to 6.8 N-M.• “AirVantage CAUTION” – Be sure to reattach the connector from the power generator to the

control board. • Reinstall the bottom cover, making sure the o-ring seal is still in the groove. Tighten• the four M5 x 16mm socket head cap screws to 3.4 N-M.• Reinstall the top cover, making sure the o-ring seal is still in the groove. Tighten the• four M5 screws. Reinstall the AirVantage using the four 5/16-18 x 5 ½ cap screws and torque to 90

in-lbs.• “AirVantage CAUTION” – Be sure to reattach the patch cable connector that connects the

AirVantage module to the intermediate.

CAPSCREW, HEX SOC HD,M5 x 0.8 x 16

COVER

SEAL, O-RING


POWER GENERATION MODULE

CONNECTOR(To Intermediate)

CONTROL MODULE

VALVE, POPPET

SEAL, O-RING

CONNECTOR (PowerGeneration Module toControl Module)

Connector (Control Moduleto Power Generation Module)

Breather Assembly

SEAL, O-RING


Note: Refer to AirVantage Composite Repair Parts List on page 23 for part numbers

AirVantage Servicing - Control Module To service the control module, first shut off and bleed the air being supplied to the pump. For safety purposes the air supply line should be disconnected from the pump. Then shut off the suction and discharge lines to the pump. Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump. During the servicing of the AirVantage, consult the “AirVantage Composite Repair Parts Drawing”.

Step #1: Remove the Patch Cable• Twist the ribbed portion of the patch cable connector in a counterclockwise direction, until it

unthreads from the connector. The cable can be removed only from the intermediate.


pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on the plastic cover located on the bottom. Inspect the o-ring between the poppet valve and the adapter plate for damage.

Step #3: Access the Pilot Valve• Use a 4mm hex-key wrench and loosen the four M5 x 16mm socket head cap screws• securing the top cover on. Lift the cover off, exposing the pilot valve. There is a molded o-ring seal

located on the underside of the cap. Make sure the o-ring stays located within the groove. The connector will need to be removed from the pilot valve. Once the plug has been removed, feed the wire assembly into the hole in the valve body to the point where the connector just enters the valve body. Reinstall the top cover and loosely reinstall the bolts. The connector will eventually need to be reconnected.

Step #4: Access the Control Module• Use a 4mm hex-key wrench and loosen the four M5 x 16mm socket head cap screws• securing the bottom cover on. Lift the bottom cover off, exposing the power generation module.

There is a molded o-ring seal located on the underside of the cap. Make sure the o-ring stays located within the groove.

• Unplug the connector that connects the power generator to the control board. Use a 4mm hex-key wrench to loosen the four M5 x 16mm socket head cap screws. The power generation module should now be loose. Carefully lift the power generation module off the rest of the assembly, making sure that the control board wire and connector slips through the hole in the power generation case.

• "AirVantage CAUTION" - Take caution not to lose the o-ring that seals between the components.

• If the control module needs to be replaced, use a 4mm hex-key wrench and loosen the four M5 x 30mm socket head cap screws holding the control module to the poppet assembly. The control module should now be loose. Carefully lift the control module off the poppet assembly, making sure that the pilot valve connector wire slips through the hole in the poppet valve assembly.

• "AirVantage CAUTION" - Take caution not to loosen the o-ring that seals between the components.

Step #5: Reinstalling• When reinstalling the new control module, make sure to feed the pilot valve connector wire through the

hole in the poppet valve assembly. Install the four M5 x 30mm socket head cap screws and tighten to 3.4 N-M.

• Reinstall the power generation module. Make sure to feed the control module wire through the hole in the power generation case. Install the four M5 x 25mm socket head cap screws and tighten to 6.8 N-M.

• “AirVantage CAUTION” – Be sure to reattach the connector from the power generator to the control board.

• Reinstall the top cover, making sure the o-ring seal is still in the groove. Tighten the four M5 screws. Reinstall the AirVantage using the four 5/16-18 x 5 ½ cap screws and torque to 90 in-lbs.

• “AirVantage CAUTION” – Be sure to reattach the patch cable connector that connects the AirVantage module to the intermediate.


COVER


SEAL, O-RING





CONTROL MODULE

VALVE, POPPET

SEAL, O-RING

SEAL, O-RING

SEAL, O-RING


AirVantage Servicing - Sensor AssemblyTo service the control module, first shut off and bleed the air being supplied to the pump. For safety purposes the air supply line should be disconnected from the pump. Then shut off the suction and discharge lines to the pump. Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump. During the servicing of the AirVantage, consult the “AirVantage Composite Repair Parts Drawing”.


from the connector. The cable can either be removed from the intermediate or from the control module.

Step #2: Remove the AirVantage from the Pump• Use a ½” socket and remove the four 5/16-18 x 5 ½ cap screws that hold the AirVantage to the pump.

Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on the plastic cover located on the bottom. Inspect the o-ring between the poppet valve and the adapter plate for damage.

Step #3: Diaphragm Disassembly• Refer to the “Diaphragm Servicing” section (p.15) of the manual to remove diaphragm assembly from

the pump. • “AirVantage CAUTION” – When the diaphragm assembly is removed, watch for the brass probe

tips located on the end of the sensor rod. There is one brass probe tip and one o-ring per side. Inspect the probe tips and o-rings for wear. For every diaphragm service, these parts should be replaced and are available in kit form. Consult the “Composite Repair Parts Drawing” for part numbers and quantities.

Step #4: Accessing the Sensor Assembly• Use a ¼” hex key wrench and remove the four, flat head socket cap screws on each inner chamber.

These bolts have been assembled using blue thread locker, so they may be difficult to remove. The inner chambers and gaskets can now be removed.

• “AirVantage CAUTION” – Remove the inner chamber from the intermediate with caution, taking care not to damage the sensor.

• If the sensor needs to be replaced, use a 13/16” socket and remove the plastic nut holding the connector to the intermediate. Slide the connector out of the hole.

• The sensor can now be removed from the intermediate assembly.

Step #5: Reinstallation• Slide the new sensor assembly in the intermediate. • “AirVantage CAUTION” – Make sure the cable assembly fits into the groove machined in the

intermediate. Failure to do so may damage the cable during assembly.• Feed the connector through the hole in the intermediate and install the plastic nut. Hand tighten the nut

using a 13/16" socket. Make sure the gasket is to the inside of the intermediate.• The inner chambers and gaskets can now be reinstalled. Use blue thread locker on the inner chamber

bolts and torque them to 300 in-lbs.• Refer to the “Diaphragm Servicing” section of the manual to finish the diaphragm installation procedure.


Page 17

PROBE TIP

O-RING

SENSOR, FEED BACK

WASHER, SEALING

PLATE, DIAPHRAGM

DIAPHRAGM

PAD, WEAR


CAPSCREW

SENSOR COVER

CAPSCREW

END CAP

FEED BACK SENSOR

O-RING

CAPSCREW

INTERMEDIATE

JAM NUT

O-RING

FOAM BUMPER

BEARING

SEAL

A

BRACKET, INTERMEDIATE, ASSEMBLYSENSOR, FEEDBACK

NUT

SEAL

DIAPHRAGM


PLATE,INNER DIAPHRAGM

PROBE TIP

O-RING

SENSOR, FEEDBACK

BUMPER

DETAIL A

FLAT EDGE


Note: Refer to AirVantage Composite Repair Parts List on page 23 for part numbers

AirVantage Servicing - Poppet Valve Drawing


COVER


SEAL, O-RING





CONTROL MODULE

VALVE, POPPET

SEAL, O-RING

SEAL, O-RING

SEAL, O-RING


AirVantage Servicing - Poppet ValveStep #1: Remove the Patch Cable

• Twist the ribbed portion of the patch cable connector in a counterclockwise direction, until it unthreads from the connector. The cable can either be removed from the intermediate or from the control module.


pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on the plastic cover located on the bottom. Inspect the o-ring between the poppet valve and the adapter plate for damage.

Step #3: Access the Pilot Valve and Pressure Regulator• Use a 5/32 hex-key wrench and loosen the four 10-32 x .50 socket head cap screws securing the

top cover on. Lift the cover off, exposing the pilot valve and pressure regulator. There is a molded o-ring seal located on the underside of the cap. Make sure the o-ring stays located within the groove.

• Unplug the connector attached to it. Use a miniature 4-way Phillips screwdriver and remove the two screws securing the pilot valve to the plate. The valve and gasket can now be removed and/or replaced.

• Use slip-joint pliers to unscrew the regulator from the body by turning it in a counterclockwise direction.

• “AirVantage CAUTION” – Do not loosen or tighten the regulator by turning the knurled portion of the unit. Place the slip-joint pliers on the smooth area underneath the knurled area of the regulator. Reinstall the top cover and loosely reinstall the bolts. Turn the assembly over and let it now rest on the top cover.

Step #4: Access the Power Generation Module• Use a 5/32 hex-key wrench and remove the four 10-32 x .50 socket head cap screws securing the

bottom cover on. Lift the bottom cover off, exposing the power generation module. There is a molded o-ring seal located on the underside of the cap. Make sure the o-ring stays located within the groove.

• Unplug the connector that connects the power generator to the control board. Use a 5/32 hex-key wrench to loosen the four 10-32 x 2 ¼ socket head cap screws. The power generation module should now be loose. Carefully lift the power generation module off the rest of the assembly, making sure that the control board wire and connector slips through the hole in the power generation case.

Step #5: Access the Control Module• Use a 5/32 hex-key wrench and loosen the two 10-32 x 1.00 socket head cap screws securing the

control module to the poppet assembly. The control module should now be loose. Carefully lift the control module off the poppet assembly, making sure that the pilot valve connector wire slips through the hole in the poppet valve assembly.

• The Poppet valve assembly can now be replaced.

Step #6: Reinstallation• Install the control module on the poppet valve assembly. Make sure to feed the pilot valve connector wire

through the hole in the poppet valve assembly. Install the two 10-32 x 1.00 socket head cap screws and tighten to 30 in-lbs.

• Install the power generation module onto the control module. Make sure to feed the control module wire through the hole in the power generation case. Install the four 10-32 x 2 ¼ socket head cap screws and tighten to 60 in-lbs.

• “AirVantage CAUTION” – Be sure to reattach the connector from the power generator to the control board.

• Install the bottom cover, making sure the o-ring seal is still in the groove. Tighten the four 10-32 screws. The unit can now be turned over and set on the bottom cover.

• Install the pilot valve, tighten the screws snug with a miniature 4-way Phillips screwdriver. • “AirVantage CAUTION” – Be sure to reattach the connector to the pilot valve.• “AirVantage CAUTION” – Be sure to reattach the patch cable connector that connects the

AirVantage module to the intermediate.• If the pressure regulator needs to be replaced, use slip-joint pliers to unscrew the regulator from the body

by turning it in a counterclockwise direction. • “AirVantage CAUTION” – Do not loosen or tighten the regulator by turning the knurled portion

of the unit. Place the slip-joint pliers on the smooth area underneath the knurled area of the regulator.

Step #4: Reinstallation• Reinstall the top cover, making sure the o-ring seal is still in the groove. Tighten the four 10-32 screws.• Reinstall the AirVantage using the four 5/16-18 x 5 ½ cap screws and torque to 90 in-lbs.• “AirVantage CAUTION” – Be sure to reattach the patch cable connector that connects the

AirVantage module to the intermediate.• Refer to Page 28 for Illustration


AirVantage - Check Valve AssemblyTo service the check valve, first shut off and bleed the air being supplied to the pump. For safety purposes the air supply line should be disconnected from the pump. Then shut off the suction and discharge lines to the pump. Bleed the pressure from the pump suction and discharge lines and remove the lines from the pump. During the servicing of the AirVantage, consult the “AirVantage Composite Repair Parts Drawing” (Page 11)

Step #1: Remove the Patch CableTwist the ribbed portion of the patch cable connector in the counterclockwise direction, until it un-threads from the connector. The cable can be either be removed from the intermediate or from the control module.

Step #2: Remove the AirVantage from the PumpUse a ½” socket and remove the four 5/16 x 5 ½ cap screws that hold the AirVantage to the pump. Remove the two chamber bolts/nuts that are holding the right side bracket to be able to remove the right bracket and the AirVantage unit from the pump. Be sure to support the weight of the AirVantage while removing the last cap screw. After the AirVantage is removed from the pump, set the unit down on the plastic cover located on the bottom. Inspect the o-ring between the poppet valve and adapter plate for damage.

Step 3: Remove the Check Valve from the PumpUse a ½” socket and remove the four 5/16 x 2 ½ cap screw that holds the check valve to the pump.

Step 4: Inspect Check ValveUsing a 1 ¼” open socket wrench, remove the cartridge valve. Inspect o-rings and mechanism for any signs of wear, degradation, or damage. If any is present, replace with new cartridge valve assembly. Remove any remaining fluid contamination on inside of body and/or cartridge valve. Be careful not to lose the large and small o-rings on either face of the check valve body.

Step 5: Re-assembly of Check ValveApply a thin layer of white lithium grease to the threads on the valve cartridge. Insert cartridge valve into body and hand-tighten being careful not to pinch o-ring. Using a 9” torque wrench with crow-foot, torque cartridge vale to 250 in-lbs. Re-apply o-rings, as necessary, to both faces of check valve. After applying Blue Loctite 248, 222 (or equivalent) secure check valve back to pump with four 5/16 x 2 ½ cap screws, re-torque to 90 in-lbs.

To secure the AirVantage, re-install the four 5/16 x 5 ½ cap screws, torquing to 90 in-lbs. Re-install Patchcable.

AirVantage Servicing - Check Valve


This 8-foot long (244 centimeters) Ground Strap, part number 920-025-000, can be ordered as a service item.

To reduce the risk of static electrical sparking, this pump must be grounded. Check the local electrical code for detailed grounding instruction and the type of equipment required.

Grounding The Pump

Take action to prevent static sparking. Fire or explosion can result, especially when handling flammable liquids. The pump, piping, valves, containers or other miscellaneous equipment must be grounded.

WARNING

One eyelet is installed to a true earth ground. (Requires a 5/16 or 8mm maximum diameter bolt)

One eyelet is fastened to the pump hardware.


CONVERTED EXHAUST ILLUSTRATION

SAFE AIREXHAUSTDISPOSALAREA

PUMP INSTALLATION AREA

1" DIAMETER AIREXHAUST PIPING

1" DIAMETER AIREXHAUST PIPING

MUFFLER

LIQUIDLEVEL

SUCTIONLINE

MUFFLER

Illustration #1

Illustration #2

PUMPING HAZARDOUS LIQUIDS• When a diaphragm fails, the pumped liquid or fumes enter the air end of the pump. Fumes

are exhausted into the surrounding environment. When pumping hazardous or toxic materials, the exhaust air must be piped to an appropriate area for safe disposal. See illustration #1 at right.

• Piping used for the air exhaust must not be smaller than 1" (2.54 cm) diameter. Reducing the pipe size will restrict air flow and reduce pump performance. When the pumped product source is at a higher level than the pump (flooded suction condition), pipe the exhaust higher than the product source to prevent siphoning spills. See illustration #2 at right.

CONVERTING THE PUMP FOR PIPING THE EXHAUST AIR• The following steps are necessary to convert the pump to pipe the exhaust air away from

the pump.• Remove the muffler. The air distribution valve has 1" NPT threads for piped exhaust.

IMPORTANT INSTALLATION NOTE: • The manufacturer recommends installing a flexible conductive hose or connection

between the pump and any rigid plumbing. This reduces stresses on the molded threads of the air exhaust port. Failure to do so may result in damage to the air distribution valve body.

• Failure to support these connections could also result in damage to the air distribution valve body.


000 Assembly, sub-assembly; and some purchased items

010 Cast Iron012 Powered Metal015 Ductile Iron020 Ferritic Malleable Iron025 Music Wire080 Carbon Steel, AISI B-1112100 Alloy 20110 Alloy Type 316 Stainless Steel111 Alloy Type 316 Stainless Steel

(Electro Polished)112 Alloy C113 Alloy Type 316 Stainless Steel

(Hand Polished)114 303 Stainless Steel115 302/304 Stainless Steel117 440-C Stainless Steel (Martensitic)120 416 Stainless Steel

(Wrought Martensitic)123 410 Stainless Steel

(Wrought Martensitic)147 Clear Anodized Aluminum 148 Hardcoat Anodized Aluminum149 2024-T4 Aluminum150 6061-T6 Aluminum151 6063-T6 Aluminum152 2024-T4 Aluminum (2023-T351)154 Almag 35 Aluminum155 356-T6 Aluminum156 356-T6 Aluminum157 Die Cast Aluminum Alloy #380158 Aluminum Alloy SR-319159 Anodized Aluminum162 Brass, Yellow, Screw Machine Stock165 Cast Bronze, 85-5-5-5166 Bronze, SAE 660167 Bronze, Alloy 954, ASTM B505 170 Bronze, Bearing Type,

Oil Impregnated

Material Codes The Last 3 Digits of Part Number

175 Die Cast Zinc180 Copper Alloy305 Carbon Steel, Black Epoxy Coated306 Carbon Steel, Black PTFE Coated307 Aluminum, Black Epoxy Coated308 Stainless Steel, Black PTFE Coated309 Aluminum, Black PTFE Coated310 PVDF Coated330 Zinc Plated Steel331 Chrome Plated Steel332 Aluminum, Electroless Nickel Plated333 Carbon Steel, Electroless

Nickel Plated335 Galvanized Steel336 Zinc Plated Yellow Brass337 Silver Plated Steel340 Nickel Plated342 Filled Nylon353 Geolast; Color: Black354 Injection Molded #203-40 Santoprene- Duro 40D

+/-5; Color: RED355 Thermal Plastic356 Hytrel357 Injection Molded Polyurethane358 Urethane Rubber

(Some Applications) (Compression Mold)359 Urethane Rubber360 Nitrile Rubber. Color coded: RED361 FDA Accepted Nitrile363 FKM (Fluorocarbon).

Color coded: YELLOW364 E.P.D.M. Rubber. Color coded: BLUE365 Neoprene Rubber.

Color coded: GREEN366 Food Grade Nitrile368 Food Grade EPDM370 Butyl Rubber. Color coded: BROWN371 Philthane (Tuftane)374 Carboxylated Nitrile

375 Fluorinated Nitrile378 High Density Polypropylene379 Conductive Nitrile405 Cellulose Fiber408 Cork and Neoprene425 Compressed Fiber426 Blue Gard440 Vegetable Fiber465 Fiber500 Delrin 500501 Delrin 570502 Conductive Acetal, ESD-800503 Conductive Acetal, Glass-Filled505 Acrylic Resin Plastic506 Delrin 150520 Injection Molded PVDF Natural color521 Conductive PVDF540 Nylon541 Nylon542 Nylon544 Nylon Injection Molded550 Polyethylene551 Glass Filled Polypropylene552 Unfilled Polypropylene553 Unfilled Polypropylene555 Polyvinyl Chloride556 Black Vinyl557 Conductive Polypropylene558 Conductive HDPE559 Glass-Filled Conductive Polypropylene570 Rulon II580 Ryton590 Valox591 Nylatron G-S592 Nylatron NSB600 PTFE (virgin material)

Tetrafluorocarbon (TFE)601 PTFE (Bronze and moly filled)602 Filled PTFE

603 Blue Gylon604 PTFE 606 PTFE 607 Envelon608 Conductive PTFE610 PTFE Integral Silicon611 PTFE Integral FKM632 Neoprene/Hytrel633 FKM (Fluorocarbon)/PTFE 634 EPDM/PTFE 635 Neoprene/PTFE 637 PTFE, FKM (Fluorocarbon)/PTFE 638 PTFE, Hytrel/PTFE 639 Nitrile/TFE643 Santoprene/EPDM644 Santoprene/PTFE 650 Bonded Santoprene and PTFE654 Santoprene Diaphragm, PTFE Overlay Balls and

seals656 Santoprene Diaphragm and

Check Balls/EPDM Seats661 EPDM/Santoprene

Delrin and Hytrel are registered tradenames of E.I. DuPont.Gylon is a registered tradename of Garlock, Inc.Nylatron is a registered tradename of Polymer Corp.Santoprene is a registered tradename of Exxon Mobil Corp.Rulon II is a registered tradename of Dixion Industries Corp.Ryton is a registered tradename of Phillips Chemical Co.Valox is a registered tradename of General Electric Co.Warren Rupp, SANDPIPER, PortaPump, Tranquilizers and SludgeMaster are registered tradenames of IDEX AODD, Inc

Declaration of Conformity

Signature of authorized person Date of issue

Printed name of authorized person

Revision Level: F

TitleDavid Roseberry Engineering Manager

October 20, 2005

Date of revisionAugust 23, 2012

Manufacturer: Warren Rupp, Inc.®, 800 N. Main StreetMansfield, Ohio, 44902 USA

Certifies that Air-Operated Double Diaphragm Pump Series: HDB, HDF, M Non-Metallic, S Non-Metallic, M Metallic, S Metallic, T Series, G Series, U Series, EH and SH High Pressure,

RS Series, W Series, SMA and SPA Submersibles, and Tranquilizer® Surge Suppressors comply with the European Community Directive 2006/42/EC on Machinery, according to Annex VIII.

This product has used Harmonized Standard EN809:1998+A1:2009, Pumps and Pump Units for Liquids - Common Safety Requirements, to verify conformance.

EC Declaration of ConformityIn accordance with ATEX Directive 94/9/EC,

Equipment intended for use in potentially explosive environments.

DATE/APPROVAL/TITLE:27 MAY 2010

Manufacturer: Warren Rupp, Inc.®, A Unit of IDEX Corportion800 North Main Street, P.O. Box 1568, Mansfield, OH 44902 USA

Applicable Standard:AirVantage Marking:EN 60079-0:2009 II 2 G DEN 60079-1:2007 Ex d ib IIB T4 GbIEC 60079-31:2006 Ex tb IIIC 135° C Db IP66

Position Sensor Rating (not marked):EN 60079-0:2006 II 2 G DEN 60079-11:2007 Ex ib IIB T4EN 61241-0:2006 Ex ibD 21 T132° CEN 61242-11:2006

0518

Airvantage-equipped ATEX-Certified Air-Operated Double Diaphragm Pump Models RHDB2. RHDF2, RS20, and RS30.

Certificate Number: Sira 10ATEX1151X Issue: 2Equiptment: AirVantage Air Flow Control Unit

Sira Certification ServiceRake LaneEcclestonChesterCH4 SJNUnited Kingdom

David Roseberry, Engineering Manager

Declaration of Conformity

David Roseberry, Engineering ManagerDATE/APPROVAL/TITLE:27 MAY 2010

Manufacturer: Warren Rupp, Inc.®, A Unit of IDEX Corportion800 North Main Street, P.O. Box 1568, Mansfield, OH 44902 USA

INTERNATIONAL ELECTROTECHNICAL COMMISSIONIEC Certification Scheme for Explosive Atmospheres

Applicable Standard:AirVantage Marking:IEC 60079-0:2004 Ex d ib IIB T4 GbIEC 60079-1:2007-4 Ex tb IIIC 135° C Db IP66IEC 60079-31:2008

Position Sensor Rating (not marked):IEC 60079-0:2007-10 Ex ib IIB T4IEC 60079-11:2006 Ex ibD 21 T132° CIEC 61241-0:2004IEC 61242-11:2005

Airvantage-equipped Air-Operated Double Diaphragm Pump Models RHDB2, RHDF2, RS20 and RS30.

Certificate Number: IECEx SIR 10.0110X Issue: 2Equiptment: AirVantage Air Flow Control Unit

Sira Certification ServiceRake LaneEcclestonChesterCH4 SJNUnited Kingdom

Documents

US Patent # 5,996,627, 6,241,487 RHDF2 Hazardous Duty ...sp.salesmrc.com/pdfs/rhdf2dl1sm_haz_duty.pdf · US Patent # 5,996,627, 6,241,487 US Patent # 7,521,921 Pending Other US Patents